Controller for setting control parameter

Abstract

A control device according to one embodiment of the present invention includes a control unit that transmits a control signal for controlling a load to a load, a sinusoidal wave generator that generates a sinusoidal wave of variable frequency and transmits it to a load, an analysis unit that analyzes a sensing current that senses a current output from a load, and a processing unit that sets control parameters of the control unit using the results of analyzing the sensing current.

Description

Technology Field

[0001] The present invention relates to a control device, and more specifically, to a control device and a method for setting control parameters that use a variable frequency sinusoidal wave to set control parameters and perform quality judgment. Background Technology

[0002] Motors possess inherent characteristics such as resistance, inductance, and friction, and these characteristic values ​​are utilized, either through measurement or design, to design position, speed, and current control logic. However, deviations exist between design values ​​and manufactured products, and even measured values ​​may be subject to measurement errors.

[0003] The motor characteristic values ​​mentioned above exhibit deviations depending on the sample and can vary due to temperature or aging. Currently, to incorporate these characteristics into the control system, controller values ​​are designed by measuring motor characteristics using multiple samples under various conditions during the development phase. However, this method introduces errors between actual samples, which consequently prevents the achievement of optimal control performance.

[0004] Due to these issues, control performance deteriorates below the design value depending on deviations between samples, temperature changes, and aging. The problem to be solved

[0005] The technical problem that the present invention aims to solve is to provide a control device and a method for setting control parameters that use a variable frequency sinusoidal wave to set control parameters and perform quality judgment.

[0006] The problems of the present invention are not limited to those mentioned above, and other problems not mentioned will be clearly understood by those skilled in the art from the description below. means of solving the problem

[0007] To solve the above technical problem, a control device according to one embodiment of the present invention comprises: a control unit that transmits a control signal for controlling a load to a load; a sinusoidal wave generator that generates a sinusoidal wave of variable frequency and transmits it to a load; an analysis unit that analyzes a sensing current that senses a current output from the load; and a processing unit that sets control parameters of the control unit using the result of analyzing the sensing current.

[0008] Additionally, it includes a voltage output unit that converts the control signal of the control unit and the sinusoidal wave into a voltage signal and transmits it to the load; and a current measuring unit that senses the current output from the load.

[0009] Additionally, the analysis unit includes a storage unit that stores the sinusoidal wave or the sensing current; and an FFT transform unit that performs a Fast Fourier Transform using the sinusoidal wave and the sensing current.

[0010] In addition, the processing unit can perform a quality determination of the load or the control device using the result of analyzing the sensing current.

[0011] In addition, the sinusoidal wave generator can generate the sinusoidal wave by receiving a mode operation signal from the control unit, production device, or upper controller.

[0012] In addition, the above sinusoidal wave generator can periodically generate the sinusoidal wave.

[0013] In addition, the above sinusoidal wave is a sinusoidal wave with a variable frequency, and a signal having one of the variable frequencies may be output for one or more cycles, or a signal with a continuously changing frequency may be output for one or more cycles.

[0014] In addition, the frequency of the above sinusoidal wave may be different from the frequency of the control signal of the control unit.

[0015] In addition, the processing unit can calculate the PI parameters, PID parameters, or filter coefficients of the control unit using the results of analyzing the sensing current.

[0016] In addition, the processing unit can set the control parameters of the control unit using the inductance and impedance of the load derived from the result of analyzing the sensing current.

[0017] In addition, the processing unit can determine the cause of the failure of the load by using the result of analyzing the sensing current.

[0018] In addition, the processing unit can determine whether the load is open-circuited, short-circuited, has increased contact resistance, has demagnetized magnet, or has reduced coil insulation.

[0019] In addition, the processing unit can estimate the temperature of the stator and rotor included in the load by determining whether there is a change in the magnetic flux strength, resistance, or inductance of the load.

[0020] In addition, the above load may be an actuator.

[0021] In addition, the control unit is a Micro Controller Unit (MCU), and the sinusoidal wave generator, the analysis unit, and the processing unit can be implemented as processors within the MCU.

[0022] To solve the above technical problem, a method for setting control parameters according to another embodiment of the present invention comprises: a step in which a sinusoidal generator generates a sinusoidal wave of variable frequency; a step in which the sinusoidal wave is transmitted to a load along with a control signal generated by a control unit; a step in which a current output from the load is sensed; a step in which the sensed sensed current is analyzed; and a step in which control parameters of the control unit are set using the result of analyzing the sensed current.

[0023] In addition, the step of analyzing the sensing current may perform a Fast Fourier Transform using the sinusoidal wave and the sensing current.

[0024] In addition, the method may include a step of determining the quality of the load or the control unit using the results of analyzing the sensing current.

[0025] In addition, the step of generating the sinusoidal wave may generate the sinusoidal wave by receiving a mode operation signal from the control unit, production device, or upper controller, or may generate the sinusoidal wave periodically.

[0026] In addition, the frequency of the above sinusoidal wave may be different from the frequency of the control signal of the control unit.

[0027] In addition, the step of setting the parameters of the control unit may set the control parameters of the control unit using the inductance and impedance of the load derived from the result of analyzing the sensing current.

[0028] In addition, the step of analyzing the sensed sensing current can determine whether there is an open circuit, short circuit, increased contact resistance, magnetic demagnetization, or reduced coil insulation of the load using the results of analyzing the sensed current.

[0029] In addition, the step of analyzing the sensed sensing current can estimate the temperature of the stator and rotor included in the load by determining whether there is a change in the magnetic flux strength, resistance, or inductance of the load using the result of analyzing the sensed current.

[0030] In addition, the above method for setting control parameters can be performed in the processor of the MCU. Effects of the invention

[0031] According to embodiments of the present invention, it is possible to determine the quality of a motor, a controller, and a state in which the controller and the motor are connected. Furthermore, it is possible to diagnose faults such as magnetic demagnetization, winding insulation reduction, winding open circuit, and winding short circuit of the motor. Additionally, it is possible to measure the controller stability (Phase Margin, Gain Margin) in the frequency domain. Furthermore, by analyzing the characteristics of a desired frequency through a sine wave generator inside the controller, it is possible to design optimal controller values ​​(P, I, D Gain and Filter). Moreover, even if the characteristics of the motor change due to changes in the motor's operating environment (temperature, aging, etc.), the motor characteristics can be measured online to obtain optimal control values, thereby maintaining the control performance (ripple in the steady state, responsiveness in the transient state, etc.) optimally at all times. Furthermore, it is possible to measure mutual interference components that were previously compensated for based on mathematical formulas, thereby enabling accurate compensation of mutual interference components.

[0032] The effects according to the present invention are not limited to those exemplified above, and various other effects are included in this specification. Brief explanation of the drawing

[0033] Figure 1 illustrates the operation of a controller according to a comparative example with the present invention. FIG. 2 is a block diagram of a control device according to one embodiment of the present invention. FIG. 3 is a block diagram of a control device according to another embodiment of the present invention. FIGS. 4 to 9 are drawings for explaining the operation of a control device according to an embodiment of the present invention. FIG. 10 is a flowchart of a method for setting control parameters according to an embodiment of the present invention. FIGS. 11 to 13 are flowcharts of a method for setting control parameters according to another embodiment of the present invention. Specific details for implementing the invention

[0034] Hereinafter, preferred embodiments of the present invention will be described in detail with reference to the attached drawings.

[0035] However, the technical concept of the present invention is not limited to some of the described embodiments but can be implemented in various different forms, and within the scope of the technical concept of the present invention, one or more of the components among the embodiments may be selectively combined or substituted.

[0036] In addition, terms used in the embodiments of the present invention (including technical and scientific terms) may be interpreted in a sense that is generally understood by those skilled in the art to which the present invention belongs, unless explicitly and specifically defined otherwise. Terms that are commonly used, such as terms defined in advance, may be interpreted in consideration of their meaning in the context of the relevant technology.

[0037] Furthermore, the terms used in the embodiments of the present invention are for the purpose of describing the embodiments and are not intended to limit the present invention.

[0038] In this specification, the singular form may include the plural form unless specifically stated otherwise in the text, and when described as "at least one of A and B and C (or more than one)," it may include one or more of all combinations that can be formed from A, B, and C.

[0039] In addition, terms such as first, second, A, B, (a), (b), etc., may be used when describing the components of the embodiments of the present invention. These terms are used merely to distinguish the components from other components and are not intended to limit the essence, order, or sequence of the components.

[0040] And, where it is stated that a component is 'connected', 'combined', or 'connected' to another component, this may include not only cases where the component is directly 'connected', 'combined', or 'connected' to the other component, but also cases where it is 'connected', 'combined', or 'connected' due to another component located between the component and the other component.

[0041] Furthermore, when described as being formed or placed "above" or "below" each component, "above" or "below" includes not only cases where two components are in direct contact with each other, but also cases where one or more other components are formed or placed between the two components. Additionally, when expressed as "above" or "below," it may include the meaning of a downward direction as well as an upward direction relative to a single component.

[0043] FIG. 1 illustrates the operation of a controller according to a comparative example with the present invention. In a controller that drives a load such as a motor, the controller (10) applies a voltage to drive the motor in the position / speed / current control logic (11) to the motor (21) through a voltage output (15), senses the current flowing according to the applied voltage in the current measurement (15), and uses the sensed current to drive the motor (21) in the position / speed / current control logic (11). The position / speed / current control logic (11) has control parameters set for driving the motor (21), and the control parameters are set using the motor's characteristic values ​​or design values. At this time, if design values ​​are used, a deviation may occur between the design values ​​and the manufactured product, and the motor's characteristic values ​​may change due to temperature changes or aging, so it may be difficult to achieve optimal control performance with the control parameters of the existing position / speed / current control logic (11).

[0044] In order to achieve optimal control performance even if errors or changes in load characteristics occur due to load characteristics, a control device according to one embodiment of the present invention can set or change control parameters using frequency response analysis. Hereinafter, a production device according to one embodiment of the present invention will be described in detail.

[0045] FIG. 2 is a block diagram of a control device according to one embodiment of the present invention.

[0046] A control device (100) according to one embodiment of the present invention is composed of a control unit (110), a sinusoidal wave generator (120), an analysis unit (130), and a processing unit (140), and may include a voltage output unit (150), a current measurement unit (160), a storage unit (131), and an FFT conversion unit (132).

[0047] The control unit (110) transmits a control signal to the load (210) to control the load (210).

[0048] More specifically, the control unit (110) controls the load (210) according to set control parameters and transmits a control signal to the load (210) to control the load (210). The load (210) connected to the control device (100) may be an actuator. Here, an actuator is a driving device that operates a device using power, and refers to a motor operated by a predetermined control unit or a piston or cylinder mechanism operated by hydraulic or pneumatic pressure. The load (210) may be a motor, and the control device (100) may be a motor driving device that drives the motor.

[0049] The sinusoidal wave generator (120) generates a sinusoidal wave of variable frequency and transmits it to the load (210).

[0050] More specifically, the sinusoidal wave generator (120) generates a sinusoidal wave of variable frequency and transmits it to the load (210) in order to determine the characteristics of the load (210).

[0051] Here, a sine wave refers to a signal whose waveform is a sine curve, and is also called a sine wave. The sine wave generator (120) transmits a sine wave with a variable frequency, and a single frequency can be output for more than one period. As shown in FIG. 4, the sine wave generator (120) is composed of a sine curve and can transmit a sine wave having a variable frequency. At this time, as shown in FIG. 4(A), the sine wave can be output such that the frequency gradually increases or gradually decreases. Alternatively, it can gradually increase and then decrease, or decrease and then increase, or it can be varied randomly. The varied frequencies can be varied linearly or exponentially. In addition, the frequency can be varied in various other ways. At this time, a signal having one of the varied frequencies can be output for more than one period. Since control parameters are measured using the response in one period, the sine wave generator (120) can output a waveform formed by a single frequency for more than one period.

[0052] Alternatively, as shown in FIG. 4(B), a signal with a continuously changing frequency may be output for more than one period. As shown in FIG. 4(B), the frequency at the start time (f S(Start) From ) to the end time (f E(End) The frequency can be varied so that it gradually increases over time. For example, it may be in the form of a chirp signal. The frequency can gradually increase or decrease, and can vary linearly or exponentially as shown in Fig. 4(B). Alternatively, it can increase and then decrease or vary randomly. In addition, the frequency can be varied in various other ways.

[0053] The sinusoidal wave generator (120) can generate a sinusoidal wave of variable frequency by receiving a mode operation signal from the control unit (110). If a reset or change of control parameters is required, the control unit (110) can control the sinusoidal wave generator (120) to generate a sinusoidal wave of variable frequency. Alternatively, the upper controller (220) can cause the sinusoidal wave generator (120) to generate a sinusoidal wave of variable frequency through a mode operation signal. When setting control parameters during the production process, the production device (220) can control the sinusoidal wave generator (120) to generate a sinusoidal wave of variable frequency. Upon receiving the mode operation signal, the sinusoidal wave generator (120) generates a sinusoidal wave of variable frequency and transmits it to the load (210).

[0054] Alternatively, the sinusoidal wave generator (120) may periodically generate the sinusoidal wave. Even without receiving a mode operation signal from the control unit (110), the upper controller (220), or the production equipment (220), a sinusoidal wave of variable frequency may be periodically generated for periodic control parameter updates. The period for generating the sinusoidal wave of variable frequency may be set in units of months or years for updating control parameters, and in units of seconds, minutes, hours, or days for fault determination of the load (210). It is obvious that it may be set to various other periods. The period for generating the sinusoidal wave of variable frequency may vary depending on the characteristics of the load (210) connected to the control device (100) or the characteristics of the control device (100), and may be set by the user. Alternatively, the sinusoidal wave generator (120) may continuously generate a sinusoidal wave by varying the frequency.

[0055] The load (210) receives a control signal from the control unit (110) and receives a sine wave of variable frequency from the sine wave generator (120). The load (210) may receive both the control signal and the sine wave of variable frequency together. At this time, the frequency of the sine wave may be different from the frequency of the control signal of the control unit. Since the frequency of the control signal for driving the load (210) and the frequency of the sine wave for setting control parameters must be distinguished, the sine wave generator (120) can generate a sine wave having a frequency different from the control signal. The sine wave generator (120) can generate a sine wave by varying the frequency to include at least one frequency different from the control signal. In generating the variable frequency, the sine wave generator (120) can vary the frequency by excluding the sine wave having the same frequency as the control signal. The response to the corresponding frequency can already be received from the control signal and analyzed. Alternatively, the frequency may be varied to include a frequency equal to the frequency of the control signal. Alternatively, the load (210) may receive the control signal and the variable frequency sinusoidal wave independently through separate input lines, or they may be applied with different input cycles.

[0056] The control signal of the control unit and the sinusoidal wave of variable frequency can be transmitted to the load (210) through the voltage output unit (150). The voltage output unit (150) can convert the control signal of the control unit (110) and the sinusoidal wave of the sinusoidal wave generator (120) into a voltage signal and transmit it to the load (210). The load (210) may be a device that operates by receiving voltage, for example, a motor, and in order to apply voltage to the load (210), the voltage output unit (150) receives the control signal and the sinusoidal wave and transmits a voltage corresponding to the corresponding frequency to the load (210) according to the frequency of the control signal and the sinusoidal wave. The voltage output unit (150) may be a bridge circuit formed by a plurality of switches. The upper switch and the lower switch forming the bridge conduct complementarily, and a three-phase voltage can be transmitted to the load (210) with a phase difference in each bridge circuit.

[0057] The analysis unit (130) analyzes the sensing current that is sensed from the load (210).

[0058] More specifically, for setting control parameters, the analysis unit (130) generates a sinusoidal wave from the sinusoidal wave generator (120) and applies it to the load (210), and analyzes the sensed current that is sensed from the load (210) according to the applied sinusoidal wave.

[0059] The current measuring unit (160) senses the current output from the load. The current measuring unit (160) is connected to the output line of the load (210) to sense the current. The current can be formed using a current measuring element such as a shunt resistor. Alternatively, the current output from the load (210) can be sensed using various devices such as a current mirror circuit and a voltage measuring device.

[0060] The sensed current sensed by the current measuring unit (160) can be used to generate a control signal in the control unit (110) and to analyze the frequency response to the control parameter in the analysis unit (130).

[0061] The analysis unit (130) can analyze the received sensing current by performing a Fast Fourier Transform on the sensing current. The Fast Fourier Transform (FFT) is a method for processing the Fourier Transform of discrete data at high speed and is used to analyze signals. By using the Fast Fourier Transform, fast processing is possible by reducing the number of time-consuming multiplications by sequentially decomposing the Discrete Fourier Transform of a long signal series into the Discrete Fourier Transform of a shorter signal series and changing the order of data using the symmetry and periodicity of the rotation factor.

[0062] The analysis unit (130) can perform a Fast Fourier Transform using the received sensing current and the sinusoidal wave transmitted to the load (210) by the sinusoidal wave generator (120). In performing the Fast Fourier Transform, the analysis unit (130) may be composed of a storage unit (131) that stores the sinusoidal wave or the sensing current and an FFT transform unit (132) that performs a Fast Fourier Transform using the sinusoidal wave and the sensing current.

[0063] A sinusoidal wave generated by a sinusoidal generator (110) and transmitted to a load (210) is branched and stored in a storage unit (131). When a sensing current corresponding to the stored sinusoidal wave is received, an FFT transform unit (132) can perform a Fast Fourier Transform using the received sensing current and the stored sinusoidal wave. The FFT transform unit (132) can determine the frequency response characteristics of the load (210) through the Fast Fourier Transform. Frequency response is a measure of what kind of response is output when an input signal of various frequencies is applied to a system, and is used to analyze the system. Here, the amplitude of the signal may be constant or change. Frequency response can represent the amplitude and phase of the signal output from the system as a curve against frequency.

[0064] The processing unit (140) sets the control parameters of the control unit (110) using the results of analyzing the sensing current.

[0065] More specifically, the processing unit (140) receives the results of analyzing the sensing current from the analysis unit (130). As previously described, the analysis unit (130) analyzes the sensing current through a Fast Fourier Transform and transmits the analyzed results to the processing unit (140). The processing unit (140) can calculate the control parameters of the control unit (110) using the results of analyzing the sensing current. The calculated control parameters can be transmitted to the control unit (110) to change or set the control parameters of the control unit (110). The control parameters are set so that the control unit (110) controls the load (210). The control parameters of the control unit (110) may vary depending on the type and characteristics of the control unit (110).

[0066] The processing unit (140) can calculate the PI control parameter, PID control parameter, or filter coefficient of the control unit (110) using the result of analyzing the sensing current.

[0067] The processing unit (140) can calculate PI control parameters if the control unit (110) is a PI controller, calculate PID control parameters if the control unit (110) is a PID controller, and calculate filter coefficients if a filter is included. The control unit (110) may be an automatic controller and may control using a combination of P, I, and D.

[0068] Here, P represents Proportional, I represents Integral, and D represents Differential. Proportional (P) control is a control method where the controlled variable is proportional to the difference between the target value and the current position; as the control value approaches the target value, the difference decreases, enabling finer control. However, when performing proportional control, as the controlled variable approaches the target value, it becomes too small to allow for further fine control, resulting in a residual deviation that remains uncontrollable. PI control utilizes both proportionality and integral forces, allowing for the elimination of this residual deviation. It eliminates the deviation by accumulating minute residual deviations over time and increasing the controlled variable based on the accumulated amount; since this is a control method that adds integral action to proportional action, it is called PI control. While PI control allows for control close to the actual target value, the controlled variable decreases as it approaches the target value, requiring operation for a certain duration. In this case, if the integer is large, the response performance in the presence of disturbances may deteriorate. In other words, it can be difficult to respond quickly to disturbances and return to the target value. To address this, differential action can be performed. In response to sudden disturbances, the deviation is observed, and if the difference from the previous deviation is large, the control input is increased to provide a response. Observing the change in the deviation from the previous time corresponds to differentiation, and PID control is performed by applying differentiation to proportional and integral operations. Even if the controlled quantity deviates from the target value, it can quickly reach the target value by applying the control amount based on the deviation from the previous time.

[0069] PID control can be expressed as a PID control equation, and PID control parameters can be represented as Kp, Ki, and Kd. PID parameters can be calculated through optimization using the step response method or the limit damping method. Correspondingly, PI control can also calculate PI control parameters Kp and Ki.

[0070] The processing unit (140) can transmit the calculated control parameter to the control unit (110) so that the control unit (110) can set or change the control parameter of the control unit (110) using the calculated control parameter. The control parameter calculated by the processing unit (140) is a control parameter calculated while the load (210) is connected. That is, it is a control parameter that is adaptively calculated by reflecting characteristic values ​​such as temperature or aging of the load (210), and corresponds to the optimal control parameter of the control unit (110).

[0071] The processing unit (140) can perform a quality determination for the control unit (210), the control device (100), or the load (210) using the results received from the analysis unit (130). When performing a quality determination during the production process, an accurate quality determination can be performed by performing a quality determination for the control unit (110) while the load (210) is connected. When performing a quality determination without connecting the control unit (110) and the load (210), problems in actual application that may occur when performing a quality determination by assuming control parameters for the other component do not occur in the control device according to the embodiment of the present invention, where the load (210) is connected to the control device (100) and parameters are measured. The processing unit (140) may perform a quality determination for the load (210) as well as the control unit (110). Since the load (210) is connected to the control unit (110), the processing unit (140) can perform a quality determination for both the control unit (110) and the load (210). That is, it can perform a quality determination for each of the control unit (110) and the load (210), or perform a quality determination for the control unit (110) and the load (210) as a set.

[0072] The processing unit (140) can determine whether the control parameter based on the result of analyzing the sensing current satisfies the quality determination criteria for the control unit (110) or the load (210). The quality determination criteria may have a lower limit and an upper limit, or may be set to a predetermined range having a lower limit or an upper limit. The quality determination criteria may be set according to the design specifications of the control unit (110) and the load (210), or according to safety or safety grade, or may be set by a user. The quality determination criteria may be stored in memory. It may also be stored as a lookup table (LUT).

[0073] The processing unit (140) can derive an inductance (L) value and a resistance (R) or impedance (Z) value from the result of analyzing the sensing current. Using the derived inductance value and resistance value or impedance value, a quality determination of the control unit (110) or the load (210) can be performed. That is, by determining whether the inductance value is within the reference range and whether the impedance value is within the reference range of the inductance, a quality determination of the control unit (110) and the load (210) can be performed.

[0074] The processing unit (140) can not only determine the quality of the load (210) using the results of analyzing the sensing current, but also determine the cause of the defect in the load (210) if it is determined that the load (210) is defective. By determining what cause the load (210) became defective and storing and accumulating the information on the cause of the defect, it is possible to identify the causes of defects that frequently occur during the production of the load (210) and to know what defects are occurring at what rate in which production line. In other words, management of the production line or production system can be performed using the information on the cause of the defect.

[0075] The processing unit (140) can derive inductance and impedance values ​​through analysis of the sensing current and can determine the cause of the defect using the inductance and impedance values. At this time, the criteria and classification for determining the cause of the defect may vary depending on the type of load (210). For example, if the load (210) is a three-phase motor and the control unit (110) drives the motor using a three-phase power supply, the processing unit (140) can determine the cause of the defect of the load (210) as open circuit, short circuit, increased contact resistance, magnet demagnetization, reduced coil insulation, etc.

[0076] The processing unit (140) may calculate the control parameters of the control unit (110) simultaneously with or after the good product determination. When the control unit (110) and the load (210) are good products, the control parameters may be calculated to set the optimal parameters for the control unit (110) while the load (210) is connected. When the control unit (110) or the load (210) is defective, the calculation of control parameters may not be performed. Alternatively, if the result according to the control parameters currently set in the control unit (110) is defective, but the defect determination is within the range where a good product determination can be obtained when the control parameters are changed, the control parameters may be changed to change the good product determination result for the control unit (110) or the load (210). Alternatively, the good product determination may be performed again after changing the control parameters. Through this, it is possible to prevent cases where a good product determination can be obtained when the control parameters are changed, but the result is determined to be defective. When performing individual quality judgments for a load (210) using fixed control parameters, or when changing control parameters, a case may occur where a defective judgment is made for a load (210) even though the load (210) could be used as a good product. However, in the production device according to the embodiment of the present invention, the possibility and accuracy of quality judgment for a load (210) can be increased by changing the result for the load (210) using a change in control parameters, in addition to quality judgment for the control unit (110) to which the load (210) is connected.

[0077] The processing unit (140) can determine whether the load (210) is faulty by using the results of analyzing the sensing current. The process of determining whether it is faulty may correspond to the process of determining whether it is a good product. Determining whether it is a good product is performed during the production process, and determining whether it is faulty may be performed during the process of controlling the load by being installed in a device or system. The processing unit (140) can determine whether it is faulty according to the fault determination criteria. The fault determination criteria may differ from the good product determination criteria. Since the good product determination is a determination for sale and the fault determination is a determination to stop operation due to a fault during current operation, the fault determination criteria may be weaker than the good product determination criteria. Unless it is a fatal fault, even if it falls within the range judged as defective during the good product determination, it may not be judged as a fault during the fault determination. That is, the standard range judged as normal rather than faulty may be wider than the standard for judging as a good product. Alternatively, it is obvious that the fault determination criteria may be the same as the good product determination criteria. The fault determination criteria may be set according to the design specifications of the control unit (110) and the load (210), or according to safety or safety grade, or may be set by the user. The fault determination criteria may be stored in the storage unit (131). It may also be stored as a lookup table (LUT).

[0078] In addition, the processing unit (140) can determine not only whether there is a failure but also the cause of the failure. It can determine what cause the failure occurred in the load (210) and provide the cause of the failure to the system or the upper controller (220) via an alarm, etc., so that the failure can be processed quickly.

[0079] The processing unit (140) can derive inductance and impedance values ​​through analysis of the sensing current and can determine the cause of the failure using the inductance and impedance values. At this time, the criteria and classification for determining the cause of the failure may vary depending on the type of load (210). For example, if the load (210) is a three-phase motor and the control unit (110) drives the motor using a three-phase power supply, the processing unit (140) can determine the cause of the failure of the load (210) as open circuit, short circuit, or increased contact resistance as shown in FIG. 5, and determine magnet demagnetization, coil insulation reduction, etc. as shown in FIG. 6. The process of determining the cause of the failure may correspond to the process of determining the cause of the defect when determining a good product.

[0080] If the impedance of a phase where an open circuit has occurred suddenly decreases to zero, it can be determined that an open circuit has occurred in the winding. Conversely, if the impedance of a phase where a short circuit has occurred suddenly increases compared to the existing value, it can be determined that a short circuit has occurred in the winding. In addition, if the resistance of a specific phase among the measured impedances increases, it can be determined that the contact resistance for that phase has increased.

[0081] At the same temperature and rotational speed, if the magnitude of the current measured at a predetermined frequency of the applied voltage—for example, in the region below 100 Hz—increases compared to the existing value, it can be determined that the magnet has been demagnetized. Additionally, if the current is high and the winding temperature rises, and the inductance measured at an applied voltage frequency of 100 Hz or higher becomes smaller than the existing value, it can be determined that the magnet has been demagnetized. If the resistance and inductance of the coil undergoing insulation reduction proceed in a direction of slightly decreasing, it can be determined that the insulation reduction phenomenon of the coil has occurred. In addition to these, various other causes of failure can be determined.

[0082] Additionally, the processing unit (140) can estimate the temperature of the stator and rotor included in the load by determining whether there is a change in the magnetic flux strength, resistance, or inductance of the load using the result of analyzing the sensing current. The load may include a stator and a rotor, such as a motor, and the load including the stator and rotor is greatly affected by temperature. Therefore, in measuring the temperature of the stator and rotor, the result of analyzing the sensing current can be used. By using the result of analyzing the sensing current, at least one of the change in the magnetic flux strength, the change in resistance, or the change in inductance of the load can be determined to estimate the temperature of the stator and rotor. In this way, the occurrence of a failure or the probability of a failure can be determined based on the estimated temperature.

[0083] The control unit is an MCU (Micro Controller Unit), and the sinusoidal wave generator, analysis unit, and processing unit can be implemented as processors within the MCU. That is, the sinusoidal wave generator, analysis unit, and processing unit can be implemented as software on a processor included in an MCU embedded in a vehicle, etc., or can be implemented in the form of hardware of a Companion Chip. When implemented in the form of hardware, it can be formed as a single piece of hardware or as separate hardware.

[0084] FIGS. 7 and 8 are drawings for explaining the operation of production equipment according to an embodiment of the present invention. As shown in FIG. 7, the control device (100) may be a control device that drives a load, a motor (210), and includes an FRA online calibration function that performs frequency response using a variable frequency sine wave. The control device (100) receives a calibration operation signal from a production device or a higher-level controller (220) and operates the motor (210) by applying a voltage containing a variable frequency sine wave. The control device (100) is connected to the motor (210), and if the motor is a three-phase motor, the three phases are connected, and if it is a DC motor, + and - may be connected. When a current is output according to the voltage applied to the motor (210), a good product determination is performed through frequency response analysis using the sensed current, and control parameters of the control unit within the control device (100) can be set. Good quality judgment information can be transmitted to a production device or an upper controller (220).

[0085] FIG. 8 is a block diagram of specific functions of a control device (100), and may be configured as an FRA online calibration including a position / speed / current control logic, a voltage output unit (150), and a current measurement unit (160) for driving a load motor (210), a sine wave generator for detecting the characteristics of the motor (210) using a variable frequency sine wave, a voltage and current signal storage memory (131), an FFT converter (132) for performing an FFT on the stored signal, and a processing unit (140) for designing and analyzing control parameters. When a calibration operation signal is transmitted from a production device or an upper controller (220) to the sine wave generator, the sine wave generator generates a variable frequency sine wave signal, and the voltage output unit (150) converts the variable frequency sine wave signal into a voltage together with the control signal output from the position / speed / current control logic and applies the voltage to the motor (210). Here, the variable frequency signal must be output for at least one cycle. For example, if signals of 1 Hz and 10 Hz are output, the 1 Hz signal must be output for at least one cycle, and then the 10 Hz signal must be output for at least one cycle. In addition, this variable frequency refers to a frequency different from the rotational frequency of the motor. For example, when the motor rotates at 600 rpm and the pole pair is 4, the voltage is applied at 40 Hz. However, in the FRA Online Calibration function, a variable signal including 40 Hz is added and applied. When the current corresponding to the applied voltage is output from the motor (210), the current measuring unit (160) senses the current and performs a Fast Fourier Transform (FFT) using the voltage and current signals corresponding to the stored variable frequency sinusoidal wave. The stored data is data corresponding to the same frequency, and the number of voltage and current data is the same.Gain and phase values ​​are calculated through FFT, and the gain and phase values ​​according to frequency are transmitted to the processing unit (140). The processing unit (140) designs and analyzes control parameters accordingly to determine a good product or calculates control parameters. The good product determination information is transmitted to a production device or a higher-level controller (220), and the control values ​​of the position / speed / current control logic are changed using the calculated control parameters. Through this, it is possible to determine a good product in the state where the motor, the control device, and the control device and the motor are connected. In addition, it is possible to measure the controller stability (Phase Margin, Gain Margin) in the frequency domain. Furthermore, it is possible to design optimal controller values ​​(P, I, D Gain and Filter) by analyzing the characteristics of the desired frequency through a sine wave generator inside the control device. In addition, even if the characteristics of the motor change as the operating environment (temperature, aging, etc.) of the motor changes, the motor characteristics can be measured online to obtain optimal control values, thereby maintaining the control performance (ripple in steady state, responsiveness in transient state, etc.) at an optimal level.

[0086] In addition, the mutual interference component of the dual motor (700) of FIG. 9 can be measured using a sinusoidal generator. Sinusoidal waves having different frequencies are applied to different motors (710 and 720), respectively, and the mutual interference component of the two motors (710 and 720) can be calculated through frequency response analysis based on the output current of each. Through this, the mutual interference component can be calculated accurately and the mutual interference component can be accurately compensated.

[0088] FIG. 10 is a flowchart of a method for setting control parameters according to one embodiment of the present invention, and FIG. 11 to 13 are flowcharts of a method for setting control parameters according to another embodiment of the present invention. The detailed description of each step in FIG. 10 to 13 corresponds to the detailed description of the method for setting control parameters in the control device of FIG. 1 to 9, and therefore, redundant descriptions will be omitted below.

[0089] In step S11, a sinusoidal generator generates a sinusoidal wave of variable frequency, and in step S12, the control unit transmits the sinusoidal wave to the load along with a control signal generated therefrom. Subsequently, in step S13, the current output from the load is sensed, and in step S14, the sensed current is analyzed. In analyzing the sensed current, a Fast Fourier Transform can be performed using the sinusoidal wave and the sensed current.

[0090] Then, using the result of analyzing the sensing current in step S14, the control parameters of the control unit are set in step S15.

[0091] In setting the parameters of the above control unit, the control parameters of the control unit can be set using the inductance and impedance of the load derived from the result of analyzing the sensing current.

[0092] In addition, the result of analyzing the sensing current in step S14 can be used to determine the quality of the load or the control unit in step S21.

[0093] In generating the above sinusoidal wave, the sinusoidal wave may be generated by receiving a mode operation signal from the control unit, production device, or upper controller, or the sinusoidal wave may be generated periodically, and the frequency of the sinusoidal wave may be different from the frequency of the control signal of the control unit.

[0094] In addition, when analyzing the sensed current, the result of analyzing the sensed current in step S14 can be used to determine whether the load is open-circuited, short-circuited, has increased contact resistance, has demagnetized magnet, or has reduced coil insulation in step S31.

[0095] In addition, when analyzing the sensed current, the temperature of the stator and rotor included in the load can be estimated by determining whether there is a change in the magnetic flux strength, resistance, or inductance of the load in step S41 using the result of analyzing the sensed current in step S14.

[0096] The method for setting control parameters according to an embodiment of the present invention can be performed in a processor of an embedded controller (MCU) formed in a vehicle, etc. That is, optimal control parameters (PID / PI / filter coefficients) can be found by using frequency response analysis (FRA). Optimal control parameters (PID / PI / filter coefficients) can be found in real-time or periodically online (or during runtime) while the vehicle is in operation by using frequency response analysis.

[0098] Meanwhile, embodiments of the present invention can be implemented as computer-readable code on a computer-readable recording medium. A computer-readable recording medium includes all types of recording devices in which data that can be read by a computer system is stored.

[0099] Examples of computer-readable recording media include ROM, RAM, CD-ROM, magnetic tape, floppy disk, and optical data storage devices. Additionally, computer-readable recording media may be distributed across networked computer systems, allowing computer-readable code to be stored and executed in a distributed manner. Furthermore, functional programs, codes, and code segments for implementing the present invention can be easily inferred by programmers in the technical field to which the present invention belongs.

[0100] As described above, the present invention has been explained by specific details such as specific components, limited embodiments, and drawings; however, this is provided merely to aid in a more comprehensive understanding of the invention, and the invention is not limited to the above embodiments. A person skilled in the art can make various modifications and variations from this description.

[0101] Accordingly, the scope of the present invention is not limited to the described embodiments, and all things equivalent to or having equivalent variations to the claims set forth below, as well as the claims set forth below, shall be considered to fall within the scope of the concept of the present invention. Explanation of the symbols

[0102] 100: Control unit 110: Control unit 120: Sinusoidal wave generator 130: Analysis Department 131: Storage section 132: FFT transform section 140: Processing unit 150: Voltage output section 160: Current measuring section 210: Subordinate 220: Production unit or upper controller

Claims

Claim 1 A control device comprising: a control unit that transmits a control signal to a load to control the load; a sinusoidal wave generator that generates a sinusoidal wave of variable frequency and transmits it to the load; an analysis unit that analyzes a sensing current that senses a current output from the load; and a processing unit that sets control parameters of the control unit using the results of analyzing the sensing current, wherein the control unit is a Micro Controller Unit (MCU), and the sinusoidal wave generator, the analysis unit, and the processing unit are implemented as processors within the MCU. Claim 2 A control device according to claim 1, comprising: a voltage output unit that converts a control signal of the control unit and the sinusoidal wave into a voltage signal and transmits it to the load; and a current measuring unit that senses the current output from the load. Claim 3 A control device according to claim 1, wherein the analysis unit comprises: a storage unit for storing the sinusoidal wave or the sensing current; and an FFT transform unit for performing a Fast Fourier Transform using the sinusoidal wave and the sensing current. Claim 4 A control device according to claim 1, wherein the processing unit performs a quality determination of the load or the control device using the result of analyzing the sensing current. Claim 5 A control device according to claim 1, wherein the sinusoidal wave generator receives a mode operation signal from the control unit, production device, or upper controller and generates the sinusoidal wave. Claim 6 A control device according to claim 1, wherein the sinusoidal wave generator periodically generates the sinusoidal wave. Claim 7 A control device according to claim 1, wherein the sinusoidal wave is a sinusoidal wave with a variable frequency, characterized in that a signal having one of the variable frequencies is output for one or more cycles, or a signal with a continuously changing frequency is output for one or more cycles. Claim 8 A control device comprising: a control unit that transmits a control signal to a load to control the load; a sinusoidal wave generator that generates a sinusoidal wave of variable frequency and transmits it to the load; an analysis unit that analyzes a sensing current that senses a current output from the load; and a processing unit that sets control parameters of the control unit using the results of analyzing the sensing current, wherein the frequency of the sinusoidal wave is different from the frequency of the control signal of the control unit. Claim 9 A control device according to claim 1, wherein the processing unit calculates the PI parameter, PID parameter, or filter coefficient of the control unit using the result of analyzing the sensing current. Claim 10 A control device according to claim 1, wherein the processing unit sets control parameters of the control unit using the inductance and impedance of the load derived from the result of analyzing the sensing current. Claim 11 A control device according to claim 1, wherein the processing unit determines the cause of failure of the load using the result of analyzing the sensing current. Claim 12 A control device according to claim 1, wherein the processing unit determines whether the load is open-circuited, short-circuited, has increased contact resistance, has magnetic demagnetization, or has reduced coil insulation. Claim 13 A control device according to claim 1, wherein the processing unit determines whether there is a change in the magnetic flux strength, resistance, or inductance of the load and estimates the temperature of the stator and rotor included in the load. Claim 14 A control device according to claim 1, characterized in that the load is an actuator. Claim 15 delete Claim 16 A method for setting control parameters, comprising: a step of generating a sinusoidal wave of variable frequency by a sinusoidal wave generator; a step of transmitting the sinusoidal wave to a load together with a control signal generated by a control unit; a step of sensing a current output from the load; a step of analyzing the sensed sensed current; and a step of setting control parameters of the control unit using the result of analyzing the sensed current, wherein the method for setting control parameters is performed by a processor of an MCU. Claim 17 A method for setting control parameters according to claim 16, wherein the step of analyzing the sensing current is characterized by performing a Fast Fourier Transform using the sinusoidal wave and the sensing current. Claim 18 A method for setting control parameters according to claim 16, comprising the step of determining the quality of the load or the control unit using the result of analyzing the sensing current. Claim 19 A method for setting control parameters according to claim 16, wherein the step of generating the sinusoidal wave is characterized by generating the sinusoidal wave by receiving a mode operation signal from the control unit, production device, or upper controller, or generating the sinusoidal wave in real time or periodically. Claim 20 A method for setting control parameters comprising: a step in which a sinusoidal wave generator generates a sinusoidal wave of variable frequency; a step in which the sinusoidal wave is transmitted to a load along with a control signal generated by a control unit; a step in which a current output from the load is sensed; a step in which the sensed sensed current is analyzed; and a step in which control parameters of the control unit are set using the result of analyzing the sensed current, wherein the frequency of the sinusoidal wave is different from the frequency of the control signal of the control unit. Claim 21 A method for setting control parameters according to claim 16, wherein the step of setting parameters of the control unit is characterized by setting control parameters of the control unit using the inductance and impedance of the load derived from the result of analyzing the sensing current. Claim 22 A method for setting control parameters according to claim 16, wherein the step of analyzing the sensed sensing current is characterized by determining whether the load is open-circuited, short-circuited, has increased contact resistance, has magnetic demagnetization, or has reduced coil insulation using the result of analyzing the sensed current. Claim 23 A method for setting control parameters according to claim 16, wherein the step of analyzing the sensed sensing current is characterized by determining whether there is a change in the magnetic flux strength, resistance, or inductance of the load using the result of analyzing the sensed current, and estimating the temperature of the stator and rotor included in the load. Claim 24 delete

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